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Presented to the Army Corrosion Summit
Daniel J. DunmireDirector, DOD Corrosion Policy and Oversight
DoD Corrosion Prevention and Control
Current Program Status
3 February 2009
Report Documentation Page Form ApprovedOMB No. 0704-0188
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1. REPORT DATE 03 FEB 2009 2. REPORT TYPE
3. DATES COVERED 00-00-2009 to 00-00-2009
4. TITLE AND SUBTITLE DoD Corrosion Prevention and Control Current Program Status
5a. CONTRACT NUMBER
5b. GRANT NUMBER
5c. PROGRAM ELEMENT NUMBER
6. AUTHOR(S) 5d. PROJECT NUMBER
5e. TASK NUMBER
5f. WORK UNIT NUMBER
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) DOD Corrosion Policy and Oversight,3000 Defense Pentagon,Wshington,DC,20301
8. PERFORMING ORGANIZATIONREPORT NUMBER
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S)
11. SPONSOR/MONITOR’S REPORT NUMBER(S)
12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited
13. SUPPLEMENTARY NOTES 2009 U.S. Army Corrosion Summit, 3-5 Feb, Clearwater Beach, FL
14. ABSTRACT
15. SUBJECT TERMS
16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT Same as
Report (SAR)
18. NUMBEROF PAGES
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19a. NAME OFRESPONSIBLE PERSON
a. REPORT unclassified
b. ABSTRACT unclassified
c. THIS PAGE unclassified
Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18
Revised law and organization in place
Strategies unchanged
DODI 5000.67 updated
Corrosion Executive assignment
Additional projects funded for 2009
University Consortium underway
New National Academies study started
1st DoD Corrosion Conference in August
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Retains the basic requirements of original public law
FY08 National Defense Authorization Act
Eliminates DoD Corrosion Executive
Adds Director of Corrosion Policy and Oversight (DCPO) with Corrosion Executive duties
Streamlines organization
Codifies Corrosion Policy and Oversight activities
FY09 National Defense Authorization Act
Requires assignment of Service Corrosion Prevention and Control Executives
Requires report to Congress on inserting corrosion planning into the acquisition process
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Director, Defense Research and EngineeringDUSD, Science and Technology
DUSD, Installations and Environment
Policy and Requirements
Training and Certification
FacilitiesOutreach and Communications
Metrics, Impact and Sustainment
Specifications/Standards and Product Qualification
• OSD• Joint Staff/J-4• Army• Navy• Air Force• Marine Corps
• Army Corps of Engineers • Joint Council for Aging Aircraft• National Aeronautics and Space Administration• US Coast Guard• Defense Logistics Agency• General Services Administration
WIPTs
IPT member representatives
DUSD, Logistics and MaterielReadiness
Science and Technology
DoD Corrosion Prevention and Control IPT
Director, Corrosion Policy and Oversight
USDAcquisition, Technology, and Logistics
DUSD, Acquisition and Technology
Army CorrosionExecutive
AF CorrosionExecutive
Navy CorrosionExecutive
Overarching strategy: transcend traditional control methods, organizations, management and fundingAttack corrosion early in construction or acquisition Focus life-cycle efforts on four primary areas
Materials and processes that prevent or reducecorrosionDetection and prognosis of corrosion Prediction of corrosion occurrencesManagement tools facilitating maintenance and materials decisions to assure acceptable levels of integrity and functionality
Publish policy and strategy direction and guidancePromote international cooperative efforts
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Implements policy – assigns responsibilities –prescribes proceduresEstablishes DoD policy requiring:
Acquisition strategies for corrosion prevention & control CPC programs to be implemented throughout life cycle CPC reporting for data collection, archiving, and feedback.
Requires Army, Navy and Air Force to:Designate a POC for oversight of corrosion mattersEstablish corrosion planning review & evaluation
Updated to reflect FY08 and FY09 National Defense Authorization Act
“Prevention and Mitigation of Corrosion on DoDMilitary Equipment and Infrastructure”
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2004/05 Air Force (USAF funded, USAF methodology) $1.5B UNK
2005/06 Army ground vehicles $2.0B 14.8%
2005/06 Navy ships $2.4B 19.8%
2006/07 DoD facilities $1.8B 15.1%
2006/07 Army aviation and missiles $1.6B 18.6%
2006/07 USMC ground vehicles $0.7B 20.8%
2007/08 Navy aviation, USMC aviation, $2.9B 31.5%
2007/08 USCG aviation and USCG ships $0.3B* 27.6%*
2008/09 Air Force aviation, Navy ships & Army ground
vehicles
TBD TBD
Year Study area
Annual
Corr.
Costs
% of
Maint.
Costs
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342 project plans submitted in 5 year period
140 projects selected
$138 million spent on projects and activitiesService project funding - $53.6 million
OSD project funding - $54.5 million
Activities funding ~ $30 million
Combined savings & return on investmentLife cycle cost avoidance - $5.75 billion
ROI: >50:1
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Army FY09 Projects Selected Joint
Project
$K OSD
Funds
$K
Match
Funds
$K Total
Funds ROI
$M
Savings
Corrosion Resistant Fences and Railings joint $230 $230 $460 28.2 $13.0
Robust HDS Manhole Sensors joint $240 $240 $480 10.4 $5.0
Corrosion Resistant Roofs with Integrated Sustainable Photovoltaic Power joint $325 $325 $650 19.5 $12.7
Structural Health and Degradation Indices for Bridges joint $435 $435 $870 17.2 $15.0
High-Voltage Capacitor Based Water Treatment for Corrosion Growth joint $362 $362 $724 16.6 $12.0
Improved Zinc Dust Primer and Coating System for Steel Structures joint $310 $310 $620 12.6 $7.8
New Generation of Corrosion Resistant Fire Hydrant Retrofits joint $215 $215 $430 19.7 $8.5
State of the Art Reinforcing Bar for Concrete Structures joint $355 $355 $710 24.6 $17.4
Innovative Corrosion Resistant Coatings and Materials for Pumps joint $285 $285 $570 16.9 $9.7
Lightweight Fiber Reinforced (Thermoset) Polymer Composite Bridge Decks joint $425 $425 $850 9.9 $8.4
Dilute Flowable Backfill Validation for Corrosion Mitigation of Buried Piping joint $175 $175 $350 12.3 $4.3
Development of Advanced CPCs for Use on Ground Equipment joint $350 $350 $700 639.0 $447.3
Corrosion Mitigation for MRAP Thru Improved Coatings joint $250 $1,103 $1,353 400.8 $542.3
Phased Array Ultrasonic (PA-UT) “In Situ” NDTE joint $350 $75 $425 120.0 $51.0
CPC Technology Implementation for Missile Weapon Systems $125 $100 $225 31.2 $7.0
FY09 Totals $4,432 $4,985 $9,417 123.3 $1,161.4
Year
$K OSD
Funds
$K Match
Funds
$K Total
Funds ROI
$M
Savings
FY05 $7,300 $8,587 $15,887 10.1 $160.9
FY06 $5,395 $6,030 $11,425 19.7 $225.2
FY07 $4,263 $4,983 $9,246 72.5 $670.4
FY08 $5,443 $5,262 $10,705 35.3 $378.1
FY09 $4,432 $4,985 $9,417 123.3 $1,161.4
Total $26,833 $29,847 $56,680 45.8 $2,596.0
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Many fundamental aspects of corrosion science and engineering are not fully understoodSusceptibility and course of corrosion in engineering materials are not reliably predictable. Advances are needed in fundamental research and basic understanding of corrosionFive universities with overlapping and complementary capabilities participatingAddresses an array of basic and applied research needs
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Realistic, Accelerated, Atmospheric Corrosion Tests Corrosion PredictionImproved Corrosion Algorithms Improved resin systemsCorrosion Mitigation By Sheltering Corrosion Sensor VerificationEffects of Washing and Clear Water Rinsing Corrosion Mechanisms For Coated Systems CPC Durability PredictionEnvironmental Degradation of Composite StructuresDegradation Effects of and Design Solutions for Composite Structures Joined to Metallic Structures Corrosion Impacts of Friction Stir Welding
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Focus - Identification of Gaps in Scientific Knowledge limiting ability to more effectively address materials degradation
Scope – National needs for both equipment and infrastructure (NIH, DOT, NRC, etc.) and not specifically DoD
Timing – Kickoff in Jan 09 with completion in 18 months
Status – Money on contract and panel selection in progress
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Education and trainingCorrosion Engineering Degree at University of Akron
Virtual corrosion simulation and gaming video
Education productions4+ training videos: public information and continuous learning
4 podcasts
1 webcast
1 Corrosion Prevention Advisory Team (CPAT) video
National Academies - National Research Council: corrosion education in the 21st century
assessed undergraduate corrosion education in engineering programs
developed recommendations for curricula that could enhance the corrosion-based skill and knowledge base of graduating engineers
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CorrDefense tri-annual epublicationSpecs & Standards assessment/qualification processAcquisition workforce corrosion training videowww.CorrDefense.gov website International cooperative effortsDoD Corrosion Conference – August 2009 featuring Congresswoman Kay Granger as keynote speaker and Congressional Staff panel
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